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FLEXmax 100 AFCI

OutBack Power FLEXmax 100 AFCI Operating instructions

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  • What is the purpose of the AFCI card replacement kit?
    Can the replacement steps be skipped if the AFCI card is not installed?
    How do you remove the bracket and standoff?
    How do you remove the insulating material?
    How do you install the new AFCI card and insulator?
    What is the purpose of the fan replacement kit?
    How do you remove the fan wire?
    How do you remove the fan box from its bracket?
    How do you remove the fan from the fan box?
    What is the purpose of the GFDI fuse replacement kit?
    How do you remove the fuse holder?
900-00262-01-001 REV A
©2019 OutBack Power. All Rights Reserved.
Instructions
FLEXmax 100 AFCI
AFCI Card Replacement Kit
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7) When inserting the new AFCI card, make certain it plugs firmly into the receptacle
in the FM100 wiring compartment (see ).
8) Using a #1 Phillips screwdriver, replace the screw in the bracket and standoff.
See .
CAUTION: Equipment Damage
Before making any changes to the system,
disconnect all sources of power (PV and battery).
!
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G
AFCI Card Replacement (SPARE-047)
NOTE: These instructions assume an AFCI (arc fault circuit
interrupter) card is installed and that both the card and sensing
coil must be replaced. Steps may be skipped if not applicable.
Steps 1 through 5 can be skipped if not previously installed.
1) Disconnect the PV wires and remove these wires from
their path through the sensing coil .
2) Using a #1 Phillips screwdriver, remove the screw from
the bracket and standoff as shown in .
3) The standoff extends through the insulating material (see
). Carefully separate the insulator from the standoff by
gently pulling to the left.
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C
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4) Remove the card (see ), insulator, and coil. These will
come off as a unit (as shown in ). The bracket will
remain in place.
5) Plug the replacement coil into the card (see ).
6) Carefully insert the new AFCI card and insulator (and coil).
The insulator must be tented over both sides of the bracket
(see ).
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NOTES
 See the charge controller literature for correct installation of PV wires on the sensing coil,
as well as general AFCI operation.
 Any parts not used may be discarded.
900-00262-01-001 REV A
©2019 OutBack Power. All Rights Reserved.
Instructions
FLEXmax 100 AFCI
Fan Replacement Kit
GFDI Fuse Replacement Kit
Fan Replacement (SPARE-046)
1)
Unplug the fan wire inside the
FM100 wiring compartment. Remove the
wire through the hole in the compartment.
2) Using a 2.5 mm hex driver, remove
the two bracket screws . Remove
the fan box from its bracket.
3) Using a #2 Phillips screwdriver, remove the
four screws holding the fan and grille
in place. Remove the fan from inside the box.
4) Remove the split bushing as shown in
and by reaching inside the box and
pressing on opposite sides of the bushing.
Remove the split bushing from the wire.
5)
Replace the fan. Install the new fan and
the old grille in the fan box by re-installing
the four #2 Phillips screws .
6) Insert the wire into the split bushing ( ),
then install the bushing in the fan box as before.
7) Install the fan box on its bracket. Seat the
box using the rear notches (located at )
and replace the 2.5 mm bracket screws .
8) Insert the fan wire into the FM100 wiring
compartment and plug in at .
Fuse Replacement (SPARE-045)
1) Remove the fuse holder .
Grip it by the top handle and
pull upward. The fuse and holder
will unsnap from the board .
2) Open the fuse holder by pushing
on the two halves of the top handle
in opposite directions as shown in
. The holder will open on a
hinge (see ).
3)
Remove the fuse
and replace it
as shown in . The replacement
fuse is rated 600 Vdc and 0.75 Adc.
4) Close the fuse holder and re-insert it
into the board .
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IMPORTANT
The fan has a manufacturer’s label
and is marked with directional arrows
(located at ). For correct airflow,
the label (and arrow) must face away
from the grille. They must be aimed
toward the body of the controller.
B
A
A
B
C
D
E
C
F
F
A
B
C
CAUTION: Equipment Damage
Before making any changes to the system,
disconnect all sources of power (PV and battery).
!
A
E
G
B
C
B
C
A
A
/